Oscillating grout applicator

ABSTRACT

An oscillating grout applicator for applying a volume of grout to a target surface includes a grout reservoir for receiving the volume of grout, the grout reservoir having an inlet and an outlet. The outlet of the reservoir is coupled to a resilient mouth, and an oscillator is operatively coupled to the resilient mouth so as to apply or transmit an oscillating motion to the resilient mouth. Momentary liquefaction of a portion of the volume of grout located within the resilient mouth occurs when the oscillating motion is applied to the resilient mouth, thereby urging the volume of grout through the resilient mouth and onto the target surface. The resilient mouth may be manufactured of a resilient rubber, or other suitable resilient material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional patentapplication No. 63/123,633 and Canadian patent application no.3,102,187, both of which were filed on Dec. 10, 2020 and are entitled“Oscillating Grout Applicator”, and both of which are incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure relates to tools for applying grout to tiles;more specifically, the present disclosure relates to an improved groutapplicator.

BACKGROUND

Installing tile on a surface, such as a floor or a wall, firstlyinvolves adhering the tiles to the surface in their desired location,positioning the tiles so that there is a narrow gap between each tileand the adjacent tiles. Grout is then applied to the narrow gaps betweenthe tiles, so as to create a substantially smooth, tiled surface withseams between the tiles filled with grout. When properly mixed, grout isa cement-like substance, which does not pour very easily (or at all) andgenerally clumps together. If there is too much water introduced to agrout mixture, so as to increase the workability of the grout, suchgrout will be of a poorer, weaker quality once cured, thereby reducingthe amount of adhesion between the grout and abutting tiles andproducing an inferior seam between the adjacent tiles. On the otherhand, when a grout mixture is prepared properly with the correct amountof water content, it has a reduced workability and it can thus be adifficult and laborious manual process to apply such a grout mixture totiles in order to complete a tiling job.

One common method for applying grout to tile is to use a trowel to placea mound of grout onto the tiled surface, and then the trowel or asqueegee is used to press the grout mixture into the gaps between thetiles and thereby create a smooth seam of grout between the tiles.Because this process involves spreading grout all over the surface ofthe tile as well, it is necessary to then wipe clean the surface of eachtile before the grout dries and hardens. Cleaning the tile after thegrout has been applied is another time consuming step in the groutingprocess. Additionally, this traditional method for applying grout totile often requires a worker to work on their hands and knees, which canbe tiring and inconvenient.

To the applicant's knowledge, previous attempts to improve on the toolsfor applying grout to tile include a grout dispensing system and devicedisclosed in the U.S. Pat. No. 8,235,621 to Robinson (hereinafter, the'621 Patent). The grout dispensing system and device disclosed in the'621 patent provides a suction mechanism that draws grout material intoan elongated tube, a dispensing channel attached to a first end of theelongated tube and a suction handle extending through the elongatedtube, wherein the suction handle draws grout into the tube when moved ina first direction and dispenses grout into the dispensing channel whenmoved in a second direction. The suction handle is operated by the userby pulling upwardly on the suction handle when grout needs to be loadedinto the dispensing system, and then the suction handle is depresseddownwardly in order to move a plunger within the elongated tube so as todeposit the grout through a plurality of dispensing tips. The systemdescribed in the '621 patent also includes a grout bucket that isseparate from the grout dispensing system, with the free end of thesuction tube placed into the grout bucket so as to draw the grout out ofthe bucket.

In U.S. Pat. No. 6,152,332 issued to Funk, a grout dispensing system isdisclosed which includes an injector having a number of user selectabledispensing nozzles that allow for selection of a desired dispensingopening diameter for a particular grouting job, and which includes apiston/plunger for forcing grout through the selected nozzle and into agap between tiles to ensure a proper amount of grout is dispensed intothe gap, The injector includes a handgrip assembly that is gripped byuser with one hand while simultaneously pushing the plunger/piston intothe injector cylinder.

In U.S. Pat. No. 1,670,677 (hereinafter, the '677 patent) issued toBrown, an apparatus for mixing and applying mortar is disclosed. Thesystem disclosed in the '677 patent includes an apparatus for mixing andthen delivering relatively dry aggregates, utilizing a plurality ofagitators to mix the mortar material, and then utilizing a combinationof the agitators and compressed air from a compressed air source to movethe mixed mortar out of the mixing chamber and through a nozzle.

In the applicant's experience, grout applicators which rely upon apiston/plunger arrangement for pushing the grout out of a container orreservoir and through a nozzle, so as to deposit the grout onto asurface, tend to clog up with grout to the extent that the grout stopsflowing out of the device after a short period of time. The issue withsuch systems for applying a grout mixture is that the application of aforce to the volume of grout within the reservoir, such as by means of aplunger/piston, tends to compact the grout mixture, thereby causing itto solidify and then cease flowing out of the nozzle. In the applicant'sexperience, such applicators may only be used for a short period of timebefore they become clogged with grout, thereby necessitating cleaningout the applicator before the grouting process can continue. Thus, thereis a need for an improved grout applicator.

SUMMARY

The applicant has discovered that applying an oscillating motion to avolume of mixed grout beneficially causes a temporary liquefaction ofthat grout mixture, thereby enabling the grout mixture to flow moreeasily through a narrow opening, allowing relatively precise depositingof the grout mixture into a narrow space or gap between two adjacenttiles. The shaking or oscillating motion breaks the surface tensionbetween the mouth or outlet of the applicator and the tile, causing thegrout to liquefy and the applicator to slide easily along the floor, theapplicator lubricated by a layer of excess water between the mouth oroutlet and the tile surface, the water being released from the groutmixture by the liquefaction process. Advantageously, providing for theflow of a grout mixture through a relatively narrow opening or mouthallows for more precise application of grout to the area where the groutis required, namely, in the space between two tiles. By allowing formore accurate dispensing of a line of grout into the area where it isrequired, it is easier and quicker to complete a grouting job becauseless tile surface needs to be cleaned after the grout has been dispensedinto place.

A further advantage of the improvements disclosed herein is that, byproviding an applicator for dispensing grout mixture into the requiredarea, it is no longer necessary for a person to manually push the groutinto the space between adjacent tiles using a trowel or similar manualtool. As such, and as will be described further below, some embodimentsof the improved oscillating grout applicator disclosed herein may beused while a person stands upright, thereby avoiding having to work onhands and knees in order to complete a tiling job, which may be lessphysically demanding for the person who is doing the grouting job.

In one aspect of the present disclosure, an oscillating grout applicatorfor applying a volume of grout to a target surface includes a groutreservoir for receiving the volume of grout, the grout reservoir havingan inlet and an outlet. The outlet of the reservoir is coupled to aresilient mouth, and the resilient mouth is operatively coupled to anoscillator so as to apply an oscillating motion to the resilient mouth.

Momentary liquefaction of a portion of the volume of grout locatedwithin the resilient mouth occurs when the oscillating motion is appliedto the resilient mouth, thereby urging the volume of grout through theresilient mouth and onto the target surface. The resilient mouth may bemanufactured of a resilient rubber, or other suitable resilientmaterial.

In some embodiments of the present disclosure, the oscillator may beoperatively coupled to the resilient mouth by a housing, the housingcomprising the oscillator, a handle and a battery compartment configuredto receive batteries for powering the oscillator. The housing and thehandle may be integrally formed as a single unit, Additionally, thereservoir may be attached to the resilient mouth at an angle of lessthan 90 degrees, so as to enable flowing of the grout from the reservoirto the resilient mouth when the grout applicator is being used to grouttile on a vertical surface, such as a wall, Furthermore, in someembodiments the oscillator may be operatively coupled to the resilientmouth by a housing, the housing comprising a handle and enclosing theoscillator, and wherein the oscillator is an electrical oscillatorpowered by an electrical power supply.

In other embodiments, the oscillator is operatively coupled to theresilient mouth through a base, wherein the base supports the resilientmouth, the reservoir and the oscillator. The oscillator may be anelectrical oscillator powered by a power source, such as batteries or anelectrical power supply. The base may include at least two wheelsrotationally mounted to the base so as to facilitate gliding the baseacross the target surface while the resilient mouth is in contact withthe target surface, The grout applicator may further include an elongatehandle having a proximate end coupled to the base and a distal enddistal from the base, wherein a user may glide the base of theapplicator across the target surface by grasping and manipulating thedistal end of the handle while the user is standing upright. Theproximate end of the elongate handle may be pivotally coupled to thebase.

In other embodiments, the oscillator may include a handle coupled to theresilient mouth and wherein the oscillating motion is generated by auser manually applying the oscillating motion to the handle, so that theoscillating motion is transmitted through the handle to the resilientmouth. Such embodiments may further include a reservoir handle attachedto the reservoir for steadying the reservoir during use of theapplicator.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side profile view of an embodiment of an oscillating groutapplicator in accordance with the present disclosure.

FIG. 1B is a close-up view of the oscillating grout applicatorillustrated in FIG. 1A.

FIG. 2A is a partially cutaway side profile view of a further embodimentof an oscillating grout applicator in accordance with the presentdisclosure.

FIG. 2B is a perspective view of the oscillating grout applicatorillustrated in FIG. 2A.

FIG. 3 is a perspective view of a further embodiment of an oscillatinggrout applicator in accordance with the present disclosure.

DETAILED DESCRIPTION

The applicant observes that liquefaction of grout occurs when it isagitated. When the water trapped within a batch of grout cannot escape,it causes the grout to become more fluid and less resistant to forceapplied to it. A shaking or oscillating action applied to a volume ofgrout increases the pressure of the water trapped within the grout,thereby temporarily liquefying even a very stiff grout mixture so longas the shaking or oscillating force is transmitted to the grout. Thesaturated sand/cement, or grout, mixture may appear quite solid untilthe application of pressure or a shock, such as the application of ashaking or oscillating motion to the mixture, initiates the liquefactionby causing the sand to form a suspension with each solid grainsurrounded by a thin film of water. This cushioning between the grainsgives grout and other liquefied sediments a spongy, fluid-like texture.

In accordance with the present disclosure, an improved oscillating groutapplicator comprises a resilient mouth, manufactured of a resilientmaterial such as a hard rubber. fitted onto a grout reservoir or hopper.The resilient mouth may have a cylindrical or frustoconical geometry,with a hollow bore running through the resilient mouth. Thus, theresilient mouth is configured to receive grout from the hopper orreservoir. An oscillating or vibrating motion is applied to theresilient mouth, thereby concentrating the pressure transmitted from theresilient mouth to the grout within the resilient mouth so as to reducethe overall amount of energy required to shake or vibrate the grout intoa liquefied state.

The resilient mouth may be advantageously sealed against the tiledsurface to which the grout is being applied, as a result of thedeformation of the opening of the resilient mouth against the tiledsurface, combined with a thin film of water escaping from the groutmixture that forms between the resilient mouth opening and the tiledsurface. Additionally, the thin film of water may facilitate sliding theopening of the resilient mouth along the tiled floor by providing somelubrication. As a result of this seal, the grout flowing through themouth opening is deposited into the desired gap between the tiles anddoes not escape the circumference of the resilient mouth opening,thereby leaving only a small amount of excess grout on the edges of thetile adjacent the gap between the tiles. Advantageously, this is a muchreduced amount of excess grout that needs to be subsequently wiped offthe tile surface, as compared to traditional methods of groutapplication which may typically leave excess grout smeared across theentire surface of the tile. The applicant has also noted that the sealcreated between the mouth opening and the tile surface forms a vacuum,which adds to the gravitational force pulling the grout downwardly fromthe reservoir to the resilient mouth, taking advantage of the grout'scohesion in the reservoir above and adjacent the resilient mouth, whereliquefaction of the grout occurs.

Additionally, the resilient mouth acts as a circular squeegee during thegrout application process, by simultaneously depositing the grout intothe gap and then levelling the grout with the tile surface as the groutmouth opening is moved along a gap between tiles.

In one aspect of the present disclosure, an oscillating grout applicator10 includes a reservoir 12, the reservoir 12 having an inlet 12 a and anoutlet 12 b. The outlet 12 b of the reservoir 12 opens into a resilientmouth 14, For example, without intending to be limiting, a resilientmouth 14 may comprise a resilient rubber sleeve or tube, wherein a firstend of the tube 14 a is adapted to couple to the outlet 12 b of thereservoir 12. The coupling between the outlet 12 b of the reservoir 12and the resilient mouth 14 may be accomplished, for example, by threadedengagement means, friction fit means, or any other suitable couplingmeans known to a person skilled in the art. The other end 14 b of theresilient mouth 14 may be supported on a base 16, such that the secondend 14 b of the resilient mouth 14 is brought into contact with a targetsurface S to which the grout will be applied. Advantageously, theresilient properties of the resilient mouth 14 enable a degree ofdeformation of the second end 14 b of the mouth 14 when in contact withtarget surface S so as to snugly fit against the target surface S,thereby enabling deposit of the grout mixture in a targeted specificarea, with minimal grout mixture being dispersed beyond the opening ofthe second end 14 b of resilient mouth 14.

As shown for example in FIG. 1B, the resilient mouth 14 may be supportedon a base 16 such that the second end 14 b of the resilient mouth 14protrudes through a lower surface 16 a of the base 16 so as to come incontact with the target surface S. In some embodiments, at least two ormore wheels 16 b may be rotatably mounted to the base 16 so as to enableeasier gliding of the base 16 across the target surface S during thegrout application. It will be appreciated by person skilled in the artthat more than two wheels may be rotatably mounted to the base 16, andthat other features which are capable of reducing friction between thebase 16 and the tiled surface S may also be employed to achieve the samepurpose; for example, a single roller or multiple rollers may berotatably mounted to the base 16 so as to enable rolling the base 16across the floor. In other embodiments, wheels or other suchfriction-reducing features may not be used, and it is understood byperson skilled in the art that such embodiments are intended to beincluded in the scope of the present disclosure.

The base 16 also supports an oscillator 18. In some embodiments, such asthe embodiment shown in FIGS. 1A and 1B, the oscillator may be anelectrical device powered by a motor which causes the oscillator 18 tooscillate, shake and/or vibrate when activated. Because the oscillator18 is mounted to the base 16, the oscillating motion generated by theoscillator 18 is transmitted through the base 16 to the resilient mouth14, which is also supported on base 16.

Advantageously, the applicant has noted that the use of a resilientmaterial in the manufacture of the resilient mouth 14, such as a rubbermaterial, facilitates transmission of the oscillating motion generatedby the oscillator 18 during use, which facilitates liquefaction of thegrout mixture that is located in the hollow cavity formed by theresilient mouth 14 when the oscillating grout applicator is in use.While in some embodiments the resilient mouth 14 is manufactured of ahard rubber, it will be appreciated by person skilled in the art thatother materials, such as plastics, which are resilient to deformationwhen a force is applied and which generally hold their shape under loadmay be suitable for the manufacture of the resilient mouth 14, and areintended to be included in the scope of the present disclosure.

In the embodiment shown in FIGS. 1A and 1B, the oscillator 18 is poweredby a source of electricity, and receives power from an electrical outletthrough the electrical cord 18 a. However, it will be appreciated thatthe oscillator may be powered by other means, such as by the use ofbatteries as will be described for further below. In other embodiments,the oscillator may also be manually operated, again as described furtherbelow.

In some embodiments, such as shown in FIG. 1B, the oscillating groutapplicator may further include an elongate handle 15. The elongatehandle may be sized so as to be comfortably used by a person who isstanding during the grouting operation, and may optionally include atelescoping handle so as to be adjustable for persons of differentheights. The handle 15 includes a grip 15 a, which grip 15 a may besized or shaped so as to be comfortably grasped by the user, and mayalso include features such as padded foam or soft rubber for the comfortof the user. In some embodiments, the handle 15 may be pivotably mountedto the base 16 by a pivotal coupling 15 b, so as to enable a greaterrange of travel by the base 16 across the target surface S when the userof the applicator stands in one position.

The applicator 10 illustrated in FIGS. 1A and 1B is employed while theuser is in a standing position, whereby the user grasps the grip 15 a inorder to move and manipulate the base 16 across a target surface Sduring a grouting operation. Grout mixture is loaded into the reservoir12 through an inlet opening 12 a, and then the electrically poweredoscillator 18 is activated to supply the oscillating motion to theresilient mouth 14, thereby liquefying the grout mixture containedwithin the cavity of the mouth 14. Thus, due to the liquefaction of thegrout mixture contained within the cavity of the resilient mouth 14, thegrout flows through the second opening 14 b of the mouth 14 and isdeposited onto the target surface S. As grout mixture exits the secondend 14 b of the mouth 14, additional grout mixture flows into theresilient mouth 14 from the reservoir 12, where it is liquefied, andthen flows through the second end 14 b, thereby providing a continuousdispensing of the grout mixture onto the target surface S. Thus, as theuser glides the oscillating base 16 across the target surface S, a lineof grout mixture is deposited into the targeted area, and simultaneouslylevelled with the tile surface, with the resilient mouth acting like acircular squeegee as it passes over the deposited grout. Once the lineof grout has been deposited into the targeted area of the target surfaceS, the user may then briefly use a trowel, sponge or cloth to remove asmall amount of excess grout from the target surface S, after which thegrouting application is complete.

It will be appreciated that while the embodiment shown in FIGS. 1A and1B may be useful for applying grout to horizontal target surfaces S,such as floors, there may be other situations which require applyinggrout to a vertical surface, such as a wall. A further embodiment of thepresent disclosure is illustrated in FIGS. 2A and 2B. As illustrated,the grout applicator 20 comprises a resilient mouth 24 having a firstend 24 a and a second end 24 b, the resilient mouth 24 comprising atubular body with a hollow cavity between first and second ends 24 a, 24b. The first end 24 a of the resilient mouth 24 is adapted to couple tothe outlet 12 b of a reservoir 12, such as by friction fit means or anyother suitable means known to a person skilled in the art. Theapplicator 2.0 further comprises a housing 26, the housing 26 enclosingan oscillator 28 and a battery compartment 28 a. The battery compartment28 a is configured for receiving batteries which power the oscillator28. In some embodiments, such as the one shown in FIGS. 2A and 28, thehousing, resilient mouth 24 and handle 25 may be formed as a single,integral unit; however, it will also be appreciated that these differentcomponents may be separately manufactured and then coupled together.

Similar to the embodiment disclosed in FIGS. 1A and 1B, the resilientmouth 24 of applicator 20 is manufactured of a relatively stiff,resilient material, which slightly deforms under load so as to betterconform to a target surface S that the second end 24 b of the resilientmouth 24 is contact with. The oscillator 28 a, which may be a motormounted to an elliptical crank or weighted crank, or may be any otheroscillator known to a person skilled in the art, the oscillating motiongenerated by the oscillator 28 is transmitted through the housing 26 ofthe applicator 20, the housing 26 being either coupled to the resilientmouth 24 or being integrally formed with the resilient mouth 24.

Although the embodiment illustrated in FIGS. 2A and 2B is powered bybatteries, it will be appreciated by person skilled in the art that theapplicator 20 may also be powered by an electrical power source, and maytherefore incorporate an electrical cord for plugging into an electricaloutlet.

Conveniently, the embodiment illustrated in FIGS. 2A and 28 may beparticularly useful in applying grout to a tiled wall or other verticaltiled surface. The version shown in FIGS. 2A and 2B is a handheld unit.Optionally, the reservoir 12 may include a handle (not shown) so thatthe reservoir may be supported and steadied by the user in one handwhile gripping the handle 25 of the applicator 20 in the other handduring use, thereby steadying the motion of the reservoir, which may beheavier and therefore require additional support when the reservoir isfilled with a volume of grout mixture. The handheld embodiment shown inFIGS. 2A and 2B may also, of course, be used in applying grout tohorizontal surfaces, such as a floor, a table surface, or the uppersurface of a wall.

In a further embodiment of the present disclosure, as illustrated inFIG. 3, an oscillating grout applicator 30 is configured to be operatedmanually. The reservoir 32, having an inlet 32 a and an outlet 32 b, isadapted to be coupled to a resilient mouth 34. As in the otherembodiments described herein, the resilient mouth 34 is a hollow andresilient tube or sleeve, having first and second ends 34 a, 34 b,wherein the first end 34 a is coupled to the outlet 32 b of thereservoir 32. The resilient mouth 34 is coupled to a manual oscillator38, which in this case comprises a handle 38 having a reservoir support38 a for coupling the oscillator to the resilient mouth 34, at one endof the oscillator 38, and a oscillator grip 38 b at the opposite end ofthe oscillator 38. The reservoir 32 further includes a reservoir handle32 c.

In use, the applicator 30 is operated by grasping the reservoir handle32 c in one hand and the oscillator grip 32 b in the other hand, andthen applying an oscillating motion to the resilient mouth 24 by movingone's hands in an oscillating motion, such as in direction D, to therebytransmit the oscillating motion through the oscillator 38 the to theresilient mouth 34.

What is claimed is:
 1. An oscillating grout applicator for applying avolume of grout to a target surface, the applicator comprising: a groutreservoir for receiving the volume of grout, the grout reservoir havingan inlet and an outlet, the outlet coupled to a resilient mouth, theresilient mouth operatively coupled to an oscillator so as to apply anoscillating motion to the resilient mouth, wherein momentaryliquefaction of a portion of the volume of grout located within theresilient mouth occurs when the oscillating motion is applied to theresilient mouth, thereby urging the volume of grout through theresilient mouth and onto the target surface.
 2. The applicator of claim1, wherein the resilient mouth is manufactured of a resilient rubber. 3.The applicator of claim 1, wherein the oscillator is operatively coupledto the resilient mouth by a housing, the housing comprising theoscillator, a handle and a battery compartment configured to receivebatteries for powering the oscillator.
 4. The applicator of claim 3,wherein the resilient mouth, the housing and the handle are integrallyformed as a single unit.
 5. The applicator of claim 1, wherein theoscillator is operatively coupled to the resilient mouth by a housing,the housing comprising a handle and enclosing the oscillator, andwherein the oscillator is an electrical oscillator powered by anelectrical power supply.
 6. The applicator of claim 1, wherein theoscillator is operatively coupled to the resilient mouth through a base,the base supporting the resilient mouth, the reservoir and theoscillator.
 7. The applicator of claim 6, wherein the oscillator is anelectrical oscillator powered by a power source selected from a groupcomprising: batteries, electrical power supply.
 8. The applicator ofclaim 7, wherein the base comprises at least two wheels rotationallymounted to the base so as to facilitate gliding the base across thetarget surface while the resilient mouth is in contact with the targetsurface.
 9. The applicator of claim 6, wherein the base furthercomprises an elongate handle having a proximate end coupled to the baseand a distal end distal from the base, wherein a user of the applicatormay glide the base of the applicator across the target surface bygrasping and manipulating the distal end of the handle while the user isstanding upright.
 10. The applicator of claim 9, wherein the proximateend of the elongate handle is pivotally coupled to the base.
 11. Theapplicator of claim 1, wherein the oscillator comprises a handle coupledto the resilient mouth and wherein the oscillating motion is generatedby a user manually applying the oscillating motion to the handle. 12.The applicator of claim 11, wherein the reservoir comprises a reservoirhandle for steadying the reservoir during use of the applicator.